Pile fabrics



Allg- 28, 1956 s. MCKNIGHT ETAL 2,760,528

PILE FABRICS Filed March 5l, 1954 Il n. 1 (gli.

ments, to Mohaseo Industries, Inc., Amsterdam, N. Y., a corporation ot New York Application March 31, 1954, Serial No. 420,108

4 Claims. (Cl. 139-402) This invention relates to pile fabrics of the type suitable for use as floor coverings yand is concerned more parncularly with a floor covering pile fabric of novel construction, which has excellent wearing qualities and can be made at low cost. The new fabric, even when made in a relatively thick, heavy construction, is highly exible but, because of the manner in which the fabric is woven, transverse exing does not cause grinning or exposure of the back or body through the pile along the line of folding. The new fabric is thus highly desirable for covering floors of irregular contour and may be employed to great advantage as carpeting for the oors of automobiles.

The fabric of the invention is distinguished from most woven carpet fabrics, in that it does not include stuifer Warps. The body of the fabric is made up of interlaced binder warp and filling yarns and the filling yarns are of a single set and lie wholly in a plane. The filling yarns are relatively stiff and may advantageously be inserted by a needle as weft shots each made up of two strands. The pile yarns are relatively heavy and are so handled as to provide a dense pile and unusually good coverage of the body.

For a better understanding of the invention, reference may be made to the accompanying drawings, in which Fig. 1 is an exploded perspective view of one form of pile fabric of the invention; and

Fig. 2 is a longitudinal sectional view of the fabric shown in Fig. l.

The floor covering fabric, of which the construction is illustrated in the drawing, is a typical example of the fabric of the invention and comprises a backing composed of binder warp yarns 10, 11 in two sets, which are interlaced with filling yarns 12. The fabric includes a single set of lling yarns, which lie wholly in a plane, and these yarns may advantageously be inserted by a needle `as double shots or picks, as shown. The binder Warp yarn picks cross over and under the filling yarns in such fashion that the yarns of one set may be considered to cross under the odd and over the even double picks along the fabric, while the yarns 11 of the other set cross over the odd and under the even double picks. In the new fabric, the binder warp yarns are arranged in groups spaced across the fabric and each such group is made up of one or more pairs of yarns, each pair consisting of one yarn of each set. In the fabric illustrated, there are two such pairs of binder warp yarns in each group. The binder warp yarns are preferably relatively light in weight and may be the usual cotton yarns used for the purpose. The filling yarns are relatively heavy and stiif and may advantageously be made of jute or paper.

The pile surface of the fabric is provided by pile yarns 13, 14 in two sets with the yarns 13 of one set crossing under the odd and over the even double picks of filling yarn along the fabric and the pile yarns 14 of the other set crossing under the even and over the odd double picks. The pile warp yarns are inserted in the fabric in groups separated by the groups of binder warp yarns and each such group of pile warp yarns is made up of one or more States Patent O 2,760,528 Patentedv Aug. 28, 1.956

ICE

pairs of yarns, each pair consisting of a yarn of each set. In the fabric illustrated there are two suchpai'rs; ofpile warp yarns in each group. The pile warp yarns are relatively heavy and are preferably made of a pluralityyof plies of singlesV yarn spun from wool or any of the blends of bers commonly used for pile yarn purposes.

In weaving the new fabric, the pile warp yarns are raised above the level of the backing over pile wires in the usual manner and, after a set of the wires has been inserted in the fabric, the lirst wire is withdrawn and reinserted. The wires are preferably of the non-cutting type, so that their removal leaves loops of the yarns raised over them but, if desired, the wires may be of the cutting type, so that the yarns raised over the Wires are cut on removal of the wires and the pile elements of the fabric are tufts. Each pile yarn thus tightly engages the under surface of alternate lling yarns along the fabric and the lengths of the yarn between the points, where it is bound beneath lilling yarns, are raised above the plane of the backing to form pile loops 15 or tuft legs.

It will be observed that, in the fabric illustrated, each group of pile yarns lying between groups of binder warp yarns is made up of a pair of pile warp yarns 13 of one set lying adjacent the groups of binder warp yarns, whilelthe middle pile warp yarns 14 of the group are of the 'oihel set. While this arrangement is preferred, the pile Warp yarns of two sets may alternate in their groups.

In the finished fabric, the binder warp yarns in a group lie close together and these yarns are of such small size that the pile warp yarns on either side of such a group overlie the group, so that the binder warp yarns are not visible at the surface of the pile. The fabric contains no stutfer warps, so that it is flexible and is, accordingly, adapted for use on tioor surfaces which are uneven or include areas of curved contour. The pile yarns are of such size that adjacent loops of a given yarn are in contact and each loop tends to lill the space between successive loops of the adjacent yarns. As a result, the pile yarns provide excellent coverage of the backing and, unless carried to an extreme, flexing of the fabric either along transverse or longitudinal lines does not expose the backing through the pile. Another advantage of the fabric is that the portions of the pile yarns looped beneath filling yarns are exposed at the back of the fabric and may thus be reached and anchored in place by a suitable coating on the back. This desirable feature of anchorage of the pile yarns by the back coating is provided at less expense than in fabrics of conventional construction containing filling yarns in two or more planes, in that less pile yarn is required for passage of the yarn from the face to the back of the new fabric than in the multi-plane fabric. The fabric thus provides a durable floor covering of good appearance and relatively 10W cost for contoured surfaces, such as the floor in the rear compartment of an automobile, which is raised to provide a tunnel for the propeller shaft.

We claim:

l. A pile fabric, which consists of interlaced iilling yarns, binder warp yarns, and pile warp yarns, the filling yarns all lying in a single plane and the binder warp yarns and the pile warp yarns each being in two sets with the yarns of one set crossing over the odd and under the even lling yarns along the fabric and the yarns of the other set crossing over the even and under the odd filling yarns, the portions of the pile warp yarns crossing under filling yarns being in tight engagement therewith and the portions of the pile warp yarns crossing over filling yarns forming pile elements lying free of the tops of the filling yarns, the binder warp yarns and the pile warp yarns being arranged in groups spaced across the fabric with each group containing at least one yarn of each set, the

groups of binder warp yarns alternating with the groups in each group are of one set and the intermediate yarns of pile Warp yarns across the fabric. of the group are of the other set.

2. A pile fabric as deined in claim 1, in which the groups of binder and pile Warp yarns each contains at References Cited in the le of this patent least two yarns of each set. 5 UNITED STATES PATENTS 3. The pile fabric of claim 1, 1n which the filling yarns 2,110,867 Castles Mar. 15 1938 are present as double picks. 2 285 332 Geben June 2 1942 4. The pile fabric of claim l, in which each group of 2,578,173 C1 ark Dec' 11: 1951 pile warp yarns includes four yarns and the outer yarns 

